Prepared shingle



April 7, 1931. T. DA. BROPHY' 1,799,500

PREPARED SHINGLE Filed Dec. 29, 192a fimw To M5 ATTORNEYS Patented Apr. 7, 1931 UNITED STATES PATENT OFFICE- THOMAS DARCY BROPHY, OF SCARSDALE, NEW YORK, ASSIGITOR TO ANACONDA SALES COMPANY, OF NEW YORK, N. Y., A CORPORATION OF DELAWARE PREPARED SHINGLE Application filed December 29, 1928. Serial No. 829,161.

This invention relates to roofing elements and is concerned more particularly with an improved roofing element or shingle of the composite type which consists of a base of non-metallic, water-resistant material of a shape and size which permits the element to be laid with others in overlapping courses in the same manner as wooden shingles, and a layer of metal covering the normally exposed end thereof to protect the base material, increase the life of the element, and improve its appearance The invention not only comprehends the new product, but also a method by which this product can be made rapidly and at low expense.

Wooden shingles as used heretofore for many years are now being rapidly displaced by prepared roofing which is cheaper to produce, ofi'ers better resistance to fire, and may be manufactured in different colors so that a roof may be given a more attractive appearance, due to the blending of the colors of the different shingles. Prepared roofing as ordinarily made consists of a felted foundation layer which is impregnated and coated with a waterproof substance, such as asphalt, and then given a layer of grit, such as crushed slate or the like, to provide a wear surface. Such roofing materials are comparatively thin so that the butt ends of the elements do not cast any considerable shadow and objections have been raised to the appearance of a roof so laid due to the thinness of the exposed butts. Also, after a considerable period of use, the action of the sun on the impregnating material is likely to cause this material to break down so that the felt rots, and this causes the exposed edges of the shingle to warp and curl, not only rendering the roof unsightly, but frequently causing leaks. In order to overcome the latter difiiculty, metal has been applied to such felted materials to produce a composite roofing element in which a coating of metal is applied .to cover the normally exposed surface. Such a roduct as this is highly satisfactory, and is 0 improved appearance, due to the presence of the metal and the weathering which it undergoes, but when the metal is applied to a base of the usual thickness, the objection still stands, that the ends of the elements are so thin that no considerable shadow is cast and the appearance of the roof is in this respect not so desirable as that of a roof covered with wood shingles or heavy tiles.

The object of the present invention is to provide a thick-butt roofing element which is relatively light in weight, of high resistance to fire, and of relatively low manufacturing cost. The new shingle afi'ords all the advantages of a metal covered roof, since the exposed part of each element is protected and concealed by a layer of metal, and in addition each element has a thickness at the butt end which approaches that of a tile. The elements, however, are much lighter than tiles and consequently are easier to lay and less expensive to ship. Also, theseelements are not subject to breakage, as is true of tiles.

In constructing the new element, I first produce a base which is made of a molded composition and is preferably in the form of a slab, a part of which is slightly tapered, while the remainder at one end of the shingle is of substantially increased thickness and tapered as the end is approached. This thickened portion includes all of the normal exosure of the element and in producing the use, the upper surface of this portion is made irregular by molding the surface with a multiphclty of crests and depressions; A layer of metal is to cover this irregular surface, and for this purpose I produce a sheet or plate of metal of appropriate form which is stamped or otherwise formed with an irregular surface containing crests and depressions which correspond exactly in shape and position to those of the irregular surface of' the thickened end of the base. The correspondence of the contour of the surface of the base with that of the metal is substantially exact so that the plate of metal may be laid on top of the thickened end of the base with the irregularities mating so that an excellent fit between the base and metal is pro vided. This production of irregularities in the base surface and in the metal itself serves several useful purposes. When the metal is placed on the base, it is anchored against lateral movement and may be held to the base I lAayer of adhesive between the base and metal.

so the roughened surface of the metal gives the element an improved appearance by reason of the texture so provided, and as themetal weathers in the course of time, the irregularities cast shadows and take on varying colors so that the total effect is highly desirable. If desired, the metal may be given different colors by appropriate treatment.

For the base I refer to employ bagasse which is produced rom sugar cane refuse an may be molded conveniently to any desired form. This material is then rendered waterproof by suitable treatment. The commercial roduct known as Celotex is entirely satisactory for the purpose after such waterproofing and a base made of this material is light in weight, resistant to weather, and not su ject to warping or other distortion arising in normal use. For the metal plate, I prefer to employ a thin sheet of copper, which may be formed by stamping in a die, the surface of which corresponds exactly to the surface of the mold in which the base plate is produced. Preferably this metal plate covers all the thickened portion of the base which has the irregular surface, and in addition includes a flat strip along one edge which extends transversely of the base and lies flat on the surface thereof. This fiat strip provides a surface over which the ends of elements of the next higher course in a roof may be laid with tight contact between the up er and lower elements. In some instances provide an additional slab of base material which is secured to the thin portion of the base and extends forwardly from the rear edge to overlie the flat strip of metal. This cover plate serves to protect the element against the seepage of water between the metal and the base a ong the rear edge of the metal. I may also provlde the metal with a flat tab or extension along one lateral edge, this tab lying in the plane of the under surface of the ele-.

ment, so as to be overlain by the next adjacent element in a course. This tab serves to close the space normally present between a pair of adjacent elements when laid, and thus protects unmetallized portions of the elements in the courses beneath. The new element includes numerous other features of novelty which will be more clearly set forth in the detailed description to follow.

For a better understanding of the invention, reference may be had to the accompanyingadrawings, in which ig. 1 shows a plan view of the new element,

' Fig. 2 is a longitudinal section thereof, 1

Fig. 3 is a diagrammatic view illustrating apparatus used for producing the parts of the element,

Figs. 4 and 5 are longitudinal sectional views on an enlarged scale showing modified forms of the element,

Fig. 6 is a fragmentary sectional view on enlarged scale showing the method of securing the base and metal together, I

Fig. 7 is a view similar to Fig. 6, showing the method of applying the cover plate, and Fig. 8 is a sectional view on an enlarged scale showing the construction of the base. Referring now to the drawings, the element is illustrated as consistin of a base 10 of molded material, preferab y of bagasse suitably waterproofed. This base is in the formof a rectangular slab of a size approximating that of the ordinar wooden shingle of commerce. The plate lias a rear portion 11 relactively thin and slightly tapered and a portion 12 of increased thickness and taper. The portion 12 lies at the butt end of the element and its thickness increases from a point 13 near the middle of the shingle forwardly to the point 14 near the extreme butt end at which point the butt tapers off sharply toward the end and sides of the slab to form splay edges 15. This base may be produced by pressing the bagasse in plastic condition to proper shape, as by means of coacting dies 16 and 17, one of which is stationary and the other movable. The material is formed by these dies to have an irregular surface 18 covering that part of the base which is of increased thickness. This rough surface includes a multiplicity of crests 19 and depressions 20 of appreciable size, and these irre larities'give the surface of the base a noticeable and attractive texture. Beyond the point 13 the base has a relatively smooth upper surface. I

The thickened portion of the base which represents the normal exposure thereof is now covered by a metallic plate 21. This plate is preferably made of a metal which is resistant to the action of the elements, and I prefer to use copper, owing to its durability and attractive appearance. A thin sheet of copper of appropriate size is formed by a stamping operation in dies to have a shape and surface corresponding exactly to the thickened portion of the base. This metal shell consequently has a multiplicity of r crests 22 and depressions 23 corresponding exactly in shape and size to crests and depressions in the base on which it is to be applied. The metal shell is ,of such dimensions as to cover the entire thickened portion of the base and to extend down to the flat under surface thereof, thus covering the edges of the base. If desired, the metal shell may be of slightly greater dimensions so that the shell may be secured to the base by turning the edges of the shell under the base, as indicated at 24.. The shell, in addition to its roughened part, also includes a portion 25 which lies flat upon the smooth surface of the base beyond the point 13. This part 25 is in the form of a strip which extends transversely of the base from one side edge to the other. The shell may also be provided with an extending tab 26 projecting from one lateral edge and lying in the plane of the under surface of the base.

In assembling the parts, a shell of a shape and size corresponding exactly to a base with which it is to be associated is placed on top of the base, with the crests and depressions of the shell in registry with those of the thickened portion of the base. The fit between the base and shell is so exact that the shell is anchored in place by the interlocking parts, and the metal can then be secured to the base simply by turning the edges of the metal beneath'the base, as indicate in Fig. 7. If desired, however, a layer of adhesive material 27 may be interposed between the base and the under surface of the metal, the ad hesive being first applied to the surface 01 the base and the metal placed thereon before the adhesive has set. The layer of adhesive used is not sufliciently thick to destroy the close fit between the base and the metal.

In some instances I find it desirable to employ a cover plate 28 for the rear surface 11 of the base. This plate is preferably a thin slab of base material having anarea approximately equal to that part of the base which is of uniform thickness. This cover plate is placed and secured to thesmooth surface of the base and at its forward end it overlies the fiat strip 25 of the metal. The plate thus rotects the element in that it prevents water rom seeping between the metal and the-base under the flat strip 25. If desired, the metaland the base may be provided with a shoulder 29 against which the forward end of the plate 28 abuts, but if this shoulder is not used, then the forward end of the plate is preferably tapered ofli, as indicated at 30, so that the element does not have a substantially increased thickness at this point. The cover plate is secured to the base by means of any ap ropriate water-resistant adhesive.-

t will be seen that the new element provides a roofing material which maybe made light in weight by the use of a base made of waterproofed bagasse, which is much lighter than an equivalent amount of impregnated felt or other material commonly used for prepared roofing purposes. The metal sheet used is very thin and serves primarily as a protective coating for the base, although it gives a roof constructed of these elements a highly desirable appearance. The amount of metal required in the ordinary element is small, due to the fact that the support afforded by the base makes it ossible to use metal of much lighter gauge t an is employed for other roofing purposes. A sheet of metal of a thickness of as little as .003" may be used satisfactorily for the purpose. By giving the base the desired molded form with the irregular surface,jand by similarly stamping or otherwise forming the shell tohave corresponding irre larities, the attachment of the metal to t e base is greatly facilitated. While the element may be produced without the use of adhesive, I prefer that a'thin layer be employed but the necessary amount of ad hesive may be sim 1y brushed or sprayed on the base without ifliculty and this adhesive serves no other purpose than that of securing the base and metal together.

The extending metal tab with which the element is provided makes it possible to lay these elements without the need of accuratel positioning the elements in one course with reference to those of the preceding course, while at the same time producing a roof entirely covered by metal. Ordinarily with the elements in a selected course spaced apart the usual distance, there are exposed through these spaces portions of the elements in the course preceding. The exposed parts of these elements are to the rear of the thickened portion and are therefore not covered with metal. It would not be desirable to apply metal to the entire upper surface of each element, because much of'the metal would serve no useful purpose and a portion of the base of each element in the lower course would be exposed between the overlying elements unless the metal shell were provided with a rearwardly extending neck or tab along the center of the element. Then, if the elements. of the course above were laid to break joint exactly with those of the precedin course, this extending neck of metal would protect the exposed portion of the lower element to the rear of the shell. Such an arrangement would require that the elements throughout the roof be laid with great exactness, but this is avoided in the present instance since each element carries a. tab which closes the space between adjacent elements. Thus the new course may be laid without reference to the position of the elements in the preceding or succeeding courses, and labor charges for laying the new product are greatly reduced. The new element, by reason of its light weight, is also much easier to handle than elements of an equivalent thickness, as now constructed, and shipping charges are greatly reduced. The new element consequently aflords all the ad vantages of a heavy tile so far as appearance on the roof is concerned, as well as the advantages of all-metal shingles with respect to long life and desirable appearance.

I claim:

1. A roofing material which comprises the combination of a preformed one-piece base of molded material having an irregular surface including a multiplicity of crests and depressions of substantial depth, and a preformed metal plate having crests and de pressions corresponding in shape and position to those of the said irregular surface, this plate being secured to the base to overlie said surface with the irregularities of the base and plate in registry.

2. A roofing element which comprises the combination of a one-piece preformed base of molded material having a portion at one end of greater thickness than the remainder of the plate, the said portion having an irregular surface including a multiplicity of crests and depressions of substantial depth, a layer of adhesive material over the said irregular surface and a preformed metal late having crests and depressions corresponding in shape and position to those of the said irregular surface, this plate being secured to the base to overlie said surface with the irregularities of the base and plate in registry by means of said layer of adhesive.

In testimony whereof I afiix my signature.

THOMAS DA. BROPHY. 

